Skill Gap Closure Training

Report Deliverables

FPA, LLC will provide a team with one or more Master Level Maintenance Supervisors and other qualified maintenance and reliability staff to perform a detailed maintenance assessment & skills gap analysis covering aspects such as organization, workflow, inventory, systems and software, key performance indicators, and training.  The deliverable will be a report with detailed findings and recommendations. A detailed assessment report will be provided upon completion of the assessment and will include the following:

  • Quantitative scorecard of the key areas
  • Observations of the current state of maintenance
  • Recommendations for improvement
  • Implementation Plan and schedule of client-selected recommendations
  • Assessing critical skills gaps

Benchmarked Averages for Labor Utilization

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Individual Assessment of 19 Core Skill Areas

  • 1 Alignment of sheaves
  • 2 Bearing & shaft maintenance
  • 3 Bearings
  • 4 Bulk handling conveyors
  • 5 Coupling shaft alignment
  • 6 Electrical safety LOTO
  • 7 Flange & piping installation
  • 8 Hand tools
  • 9 Industrial rigging principles
  • 10 Lubricants & lubrication
  • 11 Mechanical drives
  • 12 Portable power tools
  • 13 Power transmission equipment
  • 14 Pump installation & maintenance
  • 15 Pumps
  • 16 Reading blueprints
  • 17 Reading schematics
  • 18 Taking measurements
  • 19 Trouble shooting

Work Sampling Findings

Skill Gap Assessments & Closure TrainingProductivity as measured by Work Sampling is an indicator of the work process and not the caliber of the employees. We provide strategic workforce planning for all of our clients including initial assessments, ongoing education, and maintenance programs. This will include a multitude of skill gaps education materials and ongoing skills management software.

Our Work Sampling Process provides the client with an objective evaluation of its workforce productivity by identifying and quantifying barriers that impede effective work practices. Through statistical analysis of the collected data, organizations can focus efforts on mitigating or eliminating non-productive activities.

The three primary business objectives of our Work Sampling Process are to achieve desired skills improvement are:

  1. The quantitative assessment of the productivity or “wrench time” of an organization’s workforce.
  2. The quantitative assessment of barriers and skills required that impede effective work. Work Sampling Findings
  3. Recommendations for addressing identified work barriers. The work sampling process utilizes one of two methods: random sampling or worker shadowing which can evaluate productivity on a broad or detailed scale, depending on the objectives of the client.

Average ~30%
Best in Class ~60%

Various Measurement Techniques:

  • Random Sampling
  • “Shadow” Technique
  • Performed > 50 studies
  • The majority have been via random sampling
  • Measure existing skills including needed skills, current skills, and important skills to optimize the efficiency of the business.
  • One study with the shadow technique
  • Average wrench time = 37%
  • Range 20% – 49%

Measurement Technique Types:

Random Sampling

“Shadow” Technique

Average wrench time = 37%

Range 20 – 49%

Performed > 65 studies

Skilled People have fewer injuries with planned work.

We provide the following classes and subjects when assessing your business goals, skills needed, and in our skills gap analysis process.

  • Gap Assessments
  • Gap Closure Program
  • Design/Development
  • Maintenance & Operations Skills
  • Improvement Assessments
  • Craft Skills Gap Assessment
  • Operator Asset Care Training
  • Wrench Time Productivity
  • Maintenance Skills Training
  • Maintenance & Operations Skills
    Improvement Assessments

Maintenance &
Operations Skills

Measurement Technique Types:

NCCER Compatible matrix for Skills Gap Assessment and Training

1= Never heard of job task before

2= Heard of a job task before but never seen them completed before.

3, 4, 5, 6,7, 8 progressively increasing skill levels.

9= Has performed job task numerous times in a timely manner, using best practice and rework how gone to (0) ….

10= Is a master mechanic that can perform the job task in a timely manner, using best practices, knows all parts, and tools, needed for the job task, and can train best practices… Report details skill level of each staff member for Craft Skills

The report gives the probability of success with training

Skills Gap Assessment

Skills Gap Assessment

FPA delivers skills gap assessment. Results from a recent wrench time study: the client had an initial 27% wrench time utilization.

National Average

After 6 months of maintenance skills gap closure training and work control optimization, 2nd wrench time study found wrench time jumped to 49%. National Organization average wrench time 49%.

Final Results

After 12 months of skills gap closure training and work control optimization, wrench time found continued improvement as high as 70%.

Value of reducing the lost time by 50% = $92,300 per maintenance tech per year. Or $1,384,500 for 15 staff

FPA Skills Gap Closure Training

Value of reducing the lost time by 50%?
= $92,300 per maintenance tech per year.
$1,384,500 for 15 staff maintenance department.
How much capital must be spent and product sold to generate $1.4MM in profit per plant?

FPA Skills Gap Closure Training

Optimization & Process Improvement: Any Time, Anywhere in the World, We come to you.

Craft Gap Assessment

This is an onsite service conducted as an evaluation of one or more of your craftsmen. We assess the level of skill with plant maintenance tasks. It is conducted to see where your craftsmen’s skill set is rated against national benchmarks and where improvement should be made. With training for the craftsman on recommended disciplines, the reworks will decrease and the MTBF will increase. We offer on-site hands-on training that will shore up your craftsman’s skillset to achieve your maintenance goals.